Product unit-delivery apparatus

ABSTRACT

The product unit-delivery apparatus of the present invention is basically comprised of a product unit-feeder subassembly, a co-operating product unit-picker subassembly, a continuously operating electric drive motor, a drive train which intermittently and simultaneously provides the power output of the apparatus electric drive motor to the unit-feeder and unit-picker subassemblies, and adjustment components for readily adapting the apparatus to the picking of product units having different heights, different widths, or different thicknesses at very high product unit picking rates.

CROSS-REFERENCES

None

FIELD OF THE INVENTION

This invention pertains generally to automated order-filling systems,and particularly concerns improved product unit-delivery apparatus andapparatus operating methods that may be advantageously utilized in suchsystems to pick and deliver different quantities of units of a productto adjacent order-receiving containers at very-high unit delivery rates(e.g., 180 product units per minute), with ready adaptation to numerousdifferently-sized products, and without causing damage to product units.

BACKGROUND OF THE INVENTION

Automated product order-filling systems are generally well known, andtypically involve the operation of a serees of product unit deliverymachines that in sequence deliver different computer-controlledquantities of units of different products to adjacent order-receivingcontainers such as open shipping boxes as the containers aresequentially, intermittently, and incrementally indexed past the productunit delivery machine delivery outlets by cooperating,computer-controlled conveyor equipment.

One particular machine known to applicants is the article dispensingmachine disclosed in U.S. Pat. No. 5,046,641 issued to Gray. Suchmachine is designed to dispense newspapers and similar items. The priorart machine has no capability for adjustment to deliver product unitshaving a different thickness, in large part because it does not dispensearticles through an adjustable gap between a unit-feeder subassembly anda unit-picker subassembly. In Gray a feed subassembly simply advances aproduct unit into picker subassembly which moves the unit in atransverse direction away from the intersection of the twosubassemblies.

Other prior art apparatus known to Applicants includes the lift systemof U.S. Pat. No. 5,626,335 granted to Bulka et al., and the tthe bookstacker disclosed U.S. Pat. No. 4,525,118 issued to Bulka et al., andthe two-axis article loader/unloader of U.S. Pat. No. 5,611,193 grantedto Farrelly.

Such machines have heretofore posed a number of substantial operatingproblems that have remained unaddressed by the automation industry,including unnecessarily low rates of product unit-picking, inability tobe quickly changed to accommodate differently-sized products in aparticular unit-picker apparatus, and causing product unit damage,especially when high picking rates are involved.

We have discovered a novel construction for a product unit-deliveryassembly which clearly avoids the shortcomings of the known prior artautomated product delivery equipment.

Other advantages and objectives of the present invention will becomeapparent from consideration of the detailed descriptions, drawings, andclaims which follow.

SUMMARY OF THE INVENTION

The product unitlivery apparatus of the present invention is basicallyan assembly comprised of a product unit-feeder subassembly, aco-operating product unit-picker subassembly, a continuously-operatingelectric drive motor, a drive train which provides the power output ofthe apparatus electric drive motor intermittently to the unit-feeder andunit-picker subassemblies, and adjustment components for readilyadapting the apparatus to the efficient and reliable picking of productunits having different heights, different widths, or differentthicknesses at very high unit picking rates.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic side elevation view of a preferred embodiment ofthe product unit-delivery apparatus of the present invention;

FIG. 2 is a schematic top plan view of the apparatus of FIG. 1;

FIG. 3 is a schematic front elevation view of the FIG. 1 apparatus;

FIG. 4 is a schematic rear elevation view of the FIG. 1 apparatus;

FIG. 5 is a side elevation view which schematically illustrates thedrive train for the co-operating unit-feeder and unit-pickersubassemblies of the apparatus of FIGS. 1 through 4;

FIGS. 6 and 7 are top pan views, respectively, of a unit-pickersubassembly linkage that varies the linear velocity of unit-pickersubassembly picker-flight elements shown in two different operatingpositions during an incremental picker-flight element advancement;

FIGS. 8 and 9 are end elevation views of the linkage illustrated inFIGS. 6 and 7 for the two different linkage operating positions;

FIG. 10 is a side elevation view of a portion of the apparatus of FIGS.1 through 4 illustrating apparatus components for adjusting theunit-picker subassembly linkage of FIGS. 6 through 9 to accommodateproduct units of different heights.

FIG. 11 is an underside plan view of a portion of the apparatus of FIGS.1 through 4 illustrating apparatus components for adjusting theapparatus unit-feeder subassembly to accommodate product units ofdifferent widths and thicknesses;

FIGS. 12 and 13 are side section views of portions of the apparatus ofFIGS. 1 through 4 illustrating apparatus components for adjusting theproduct delivery gap situated intermediate the unit-feeder andunit-picker subassemblies to accommodate product units of differentthicknesses;

FIGS. 14(a) through 14(c) are graphs schematically illustratingrepresentative drive chain and picker flight linear velocity conditionssimultaneously existing in the invention apparatus during the pickingand delivery of product units, and

FIG. 15 is a graph illustrating schematically picker flightaccelerations which typically occur during a picking sequence performedby the invention apparatus.

DETAILED DESCRIPTION

The product unit-delivery apparatus of the present invention istypically utilized in automated order-filling equipment systems in whichpre-programmed, computer-generated signals are directed to the equipmentproduct unit delivery machines to control alternate activation anddeactivation that obtains picking and delivery of varied quantities ofproduct units. Normally an open shipping container is movedincrementally along by a conventional conveyor and stopped at eachsystem product unit delivery machine product discharge chute for a brieftime so that the machine unit-picker subassembly may be activated by aconventional computer-controlled input signal to pick and deliver to theopen shipping container the prescribed number of units of a particularproduct required by the order then being filled. Such shipping containeris then advanced by its computer-controlled conveyor to the next productunit delivery machine in the order-filling system battery or series ofproduct unit delivery machines where, if required by the pertinentorder, it is provided with the required number of units of a differentproduct. Typically, the product unit delivery apparatus of the presentinvention may be readily adjusted and utilized to efficiently pickdifferent products from a range of books, pamphlets, pre-packaged audiocompact discs, pre-packaged data compact discs, pre-packaged videocassettes, and the like. Delivery of a predetermined quantity of productunits is accomplished by the apparatus incrementally and at rates of upto 180 product units per minute using state-of-the-art systemcomponents.

As illustrated in FIGS. 1 through 5 of the drawings, our productunit-delivery apparatus invention 10 is basically comprised of a rigidstructural frame assembly 12 mounted on base element 14, a unit-feedersubassembly 16 supported by frame 12, and a co-operating unit-pickersubassembly 18 that also is supported by frame element 12. Aconventional electric motors 20 is supported by base element 14 andfunctions to power system 10 through the drive train 22 thatco-operatively connects the output shaft of electric motor 20 tounit-feeder subassembly 16 and to unit-picker subassembly 18.

Also shown in FIG. 1 is the product unit delivery apparatusdeflector-like, delivery chute 19 which receives successive units ofproduct P from unit-picker subassembly 18 for delivery to the shippingcontainer SC that is positioned in place by conveyor C. Delivery chute19 co-operates with an adjustable-width apparatus product unit deliverygap that exists between subassemblies 16 and 18 and that is laterdescribed in connection with FIGS. 12 and 13. Unit-feeder subassembly 16normally has a proportionally much greater length than thatschematically illustrated in the drawings and typically supports a fargreater number of product units P than the relatively few shown inoutline in FIG. 1 and thereby minimizes the need of frequent subassemblyfilling with product units taken from product inventory. If desired, anadditional conveyor or conveyors can be added to apparatus 10 in serieswith subassembly 16.

Drive train 22 includes the output shaft 24 of electric motor 20 and itsattached drive sprocket 26, driven sprocket 28 keyed to a conventionalelectromagnetic clutch mechanism 30, an endless chain 29 thatinterconnects sprockets 26 and 28, and an output shaft 32 that isincrementally activated and driven by clutch mechanism 30 and that has arigidly attached output sprocket 34 which drives unit-picker subassembly18 and a rigidly attach output cam 36 that drives unit-feedersubassembly 16. Electromagnetic clutch mechanism 30 is a so-calledstate-of-the-art “one-revolution” device; when computer-controlledthrough one cycle of activation and deactivation to cause picking anddelivery of one unit of product, mechanism 30 effects but one completerevolution of connected output shaft 32 by electric motor 20 and powertrain 22. Also, clutch mechanism 30 is basically activated/deactivatedin response to electrical/electronic input signals received by apparatus10 from a computer-controlled automated order filling system.

Referring to FIGS. 2 and 5, unit-feeder subassembly 16 is principallycomprised of multiple endless rubber gear belts 40 which co-operate withtoothed drive sprockets 42 mounted on-a drive shaft 43 and with followersprockets 44 keyed to shaft 45 and upon which the stacked product unitsP are supported and carried, of adjustable side rails 46 and theirmanual separation control mechanism 47, of a manual delivery gap controlmechanism 48, and of a subassembly drive train 50 that co-operablyconnects subassembly 16 to apparatus cam element 36. Gear belts 40 aretensioned by spring assembly 49 shown in FIG. 11. Unit-feedersubassembly shaft elements 43 and 45 are each rotatably supported byapparatus frame 12.

Subassembly drive train 50 is best illustrated in FIG. 5 as beingessentially a three-bar linkage comprised of gear-segment bar 52,intermediate bar 54, and bar 56 having an adjustable effective length.Bars 52 and 56 co-operate with and are reciprocally rotated about fixedpivot points 58 and 60, respectively, and are connected to intermediatebar 54 by fixed pivot connection 61 and by adjustably-positioned pivotconnection 62. Bar 56 has an attached extension 64 that carries the camfollower 66 which co-operates with cam element 36 of machine drive train22. Bar element 52 includes a sector gear 70 that meshes with a toothedgear 68 rotatably mounted on drive shaft 43, and that through aso-called “one-way” clutch bearing (e.g., Torriington Type DC rollerclutch) 71 couples gear 68 to drive shaft 43 and thereby imparts onlyone-way, incremental rotational motion to subassembly shaft element 43.

Adjustments to drive train 50 so that unit-feeder apparatus 16 canproperly feed product units of different thicknesses are made bychanging the position of pivot connection 62 in co-operatinglongitudinal slot 63 which changes the effective length of bar element56 to thereby change the stroke of arm 52. These changes adjust thedistance the endless rubber gear belts 40 are advanced with eachcomplete revolution of cam element 28. Ideally, the distance of eachbelt incremental advance is equal to the thickness of a single productunit P.

Also, referring to FIGS. 2 and 5, unit picker subassembly 18 isprincipally comprised of an adjustable stop subassembly 72 carried byapparatus frame 12, and a fixed-position, variable-velocity, unit-pickersubassembly 74 also carried by apparatus frame 12. Stop subassembly 72positions a product unit to be picked on unit-picker subassembly 18.Subassembly 72 is comprised of spaced-apart stop-bar elements 76, stopframe elements 78 connecting stop bars 76 into a unitary structure, anda hereinafter-described, manually-powered position adjustment feature 80that is utilized to position subassembly 72 properly with respect tosubassembly 74 so that the projecting picker finger elements 84 carriedby apparatus picker flights 82 are positioned properly in relation tothe thickness of the product units being picked from unit-feedersubassembly 16 and delivered by apparatus 10 for shipment.

Unit-picker subassembly 74 is comprised of multiple, spaced-apart,product picker flights 82 that are attached to endless drive chains 86and that each include and carry multiple product picker fingers 84.Endless drive chains 86 cooperate with drive sprockets 88 and followersprockets 90 which respectively are keyed to a drive shaft 92 and afollower shaft 94. Such shafts are rotatably supported in apparatusframe 12. A drive train subassembly 98 connects drive shaft 92 to theoutput sprocket 34 of apparatus drive train 22. It should be noted thatgearing ratios in apparatus 10 are controlled so that one revolution ofapparatus drive shaft 32 causes but one revolution of drive shaft 92,that one revolution of unit-picker subassembly drive shaft 92 causeseach picker flight 82 attached to endless chains 86 to be advancedthrough but one pick cycle, and also that one revolution of unit-pickersubassembly drive shaft 32 causes but one cycle of reciprocation oflinkage bar 52 of unit-feeder subassembly drive 50.

Drive train means 98 is detailed best in FIGS. 6 through 10 of thedrawings, and principally inclincludes a velocity-modification linkage100 which functions to provide a so-called “soft-touch” characteristicor capability to picker finger elements 84 and picker flights 82 as eachsuch element nears and initially contacts a product unit for picking anddelivery. Drive chain 102 co-operates with a sprocket element 106 inlinkage 100 and is driven by drive sprocket 34 of drive train 22. Aconventional chain tensioning assembly 103 contacts drive chain 102 andmaintains the same in a proper taut condition. Linkage 100, developingthe velocity characteristics schematically and more clearly illustratedin FIG. 14(c), actually completely stops each flight 82/finger 84combination just before product unit contact with a product unit P. Theproduct-picking flights also stop completely following delivery of eachpicked product unit input signal sequence but that cessation of motionis caused by the inactivation of “one-revolution” clutch mechanism 30 inapparatus drive train 22. The point of picker flight zero aerationduring one rotation or cycle of unit-picker subassembly drive shaft 92is, because of the high rate of rotation of cam element 126,instantaneous in nature, and the picker-flight velocity that resultsfrom manual adjustment or repositioning of cam element 126 frequently isvery near and sometimes precisely at the chain absolute zero velocity(acceleration reversal) position. However, the terms “zero velocity” and“zero acceleration” as used in this description and in the claims whichfollow are intended to include the near-zero as well as the absolutezero.

Note from FIG. 14 that all velocities V are illustrated as a function oftime T, and that the linear velocity V (29) of drive chain 29 has aconstant and continuous value, that the linear velocity V (102) of drivechain 102 which connects linkage 100 to sprocket 34 of apparatus drivetrain 22 intermittently falls to a zero value as the result of operationof clutch mechanism 30 in drive train 22, and that the linear velocity V(86) of drive chains 86 in the apparatus unit-picker subassembly ismodified by the functioning of linkage 100 so as to additionally have azero value at the intermediate pick point pp which coincides withinitial product unit contact by flight picker fingers 84. Also note thatFIG. 14 schematically illustrates two picking sequences; the first isfor picking but a single product unit P whereas the second sequence isfor a picking of three product units P.

In FIG. 15 we illustrate the picker flight linear velocity changes thatare achieved with velocity-modification linkage 100 in the form ofacceleration/deceleration A changes as a function of time T. The 0.33second time value included in FIG. 15 relates to apparatus picking at arate of approximately 180 product units per minute. Also, as will bedeveloped in the following more-detailed description ofvelocity-modification linkage 100, the time position of pick point pp ofeach product unit pick relative to the beginning and end of the machineincremental pick cycle period can be time-shifted within a unit deliverycycle by repositioning the timing cam included in velocity modificationlinkage mechanism 100 to accommodate picking product units of adifferent height.

Referring to FIGS. 6 through 10, velocity-modification linkage 100 isbasically comprised of: crank 104 that is pinned to sprocket 106 (whichis driven by chain 102 and sprocket 34 of drive train 22, and whichrotates freely about shaft 92) and that has an integral crank arm 108;link 110 (that is connected to crank arm 108 by pivot connection 112 andcarries cam follower element 114); link 116 (that is connected to link110 by pivot connection 118 and that is provided with an integralclearance relief cut 120); and crank arm 122 (that is rigidly secured todrive shaft 92 by set screw device 124 and that is connected to link 122by pivot connection 121). Linkage 100 further comprises timing cam 126rigidly affixed to frame 12 (which guides movement of cam followerelement 114 as linkage crank arm 108 makes a complete revolution aboutshaft 92); and torsion spring 128 (that is connected at each end to oneof crank arms 108 and 122 and that functions to “open” linkage 100following its “closure” as a result of cam follower 114 riding over thecontinuously curved segment of cam element 126).

Another embodiment of linkage 100 not detailed in the drawingseliminates the need of having a torsion spring element such as 128 inthe linkage. Basically, the alternate embodiment has cam follower 114co-operating with a recessed, essentially uniform-width, groove that isincluded in rotatable cam element 126, that has a groove planconfiguration that corresponds to the configuration of the cam surfaceof illustrated cam element 126, and that achieves the required camfollower return or closure movement.

From the above it may be seen that input drive sprocket 106 is connectedto power out shaft 92 through links 108, 110, 116 and 122. Because drivesprocket 106 rotates at constant speed, drive arm 108 which is rigidlyaffixed thereto also rotates at a constant speed. As mentionedpreviously drive arm 108 is attached to link 110 through a pivotedconnection 112. Link 110 includes a cam follower 114 fixedly mountedthereon. Follower 114 rides along the outer surface of a fixed cam 126rigidly mounted to a frame member 12. Referring to FIG. 7, it may beseen that a spring 128 acts to bias links 108 and 122 apart. It alsoserves to keep follower 114 in position with respect to cam 126. Asfollower 114 traverses the outer surface of cam 126 it causes link 110to move radially inwardly and outwardly and to thereby pivot link 110about pivot 112. This in turn causes pivot 118 to move radially inwardlyand outwardly. As pivot point 113 is moved radially outwardly, link 116moves radially outwardly which in turn causes link 122 to be rotatedtowards arm 108 and against the rotational direction of arm 108. Becauselink 122 is rigidly affixed to output shaft 92 this in turn causes therotation of shaft 92 to increase.

Conversely, when cam follower 114 traverses the outer surface of cam 126and is moved radially inwardly, such causes pivotal connection 118 andlink 116 to move radially inwardly. This in turn speeds the rotation ofpivot point 121 and link 122 away from arm 108 to cause link 122 andshaft 92 to slow down and in some cases come to almost a complete stop.

In summation, follower 114 simply causes pivot 118 to move radiallyinwardly and outwardly as it traverses the outer surface of cam 126.This causes a scissors action with respect to links 108 and 122 in thatit causes them to move toward and away from each other. As link 122 ismoved towards arm 108 shaft 92 is speeding up. When link 122 is movedaway from arm 108 the rotational speed of shaft 92 is decreased. Timingcam 126 also has a pick-point pp (see FIGS. 8 and 9) where its camsurface has a minimum radius that during one revolution of timing cam126 coincides time-wise with and establishes the position of pick-pointpp noted in FIGS. 14 and 15.

As described in the previous discussion relating to FIG. 14, linkage 100functions to modify the linear velocity of unit-picker subassemblyflight/finger combinations 82/84 from the velocity condition of FIG.14(b) to that shown in FIG. 14(c) by varying the rate of rotation ofdrive shaft element 92 with a complete cessation of shaft rotationoccurring at the product unit pick-point pp where a flight finger 84initially contacts a product unit. It is also possible to accomplish thelinear velocity modification function associated with linkage 100 withincluded electronic circuit means in preference to a pure mechanicalcomponent construction.

FIG. 10 best illustrates the construction features provided in apparatus100 to vary the position of pick point pp in a product unit pick toaccommodate product units of different height. Such basically involvesrotation of cam 126 relative to drive shaft 92 and apparatus frame 12,and is accomplished by loosening threaded lock-screw 130 which engages acorrespondingly threaded hole in timing cam 126 and which co-operateswith circular slot 132 provided in apparatus frame 12, rotating timingcam 126 to its appropriate new position, and re-tightening threadedlock-screw 130 to securely clamp timing cam 126 to apparatus frame 12.

FIG. 11, which essentially is a partial view of apparatus 10 frombeneath unit-feeder subassembly 16, provides details of the manualcentering mechanism which adjustably controls the separation positioningof side rails 46 of unit-feeder subassembly 16. Such mechanism isessentially a manually-turned lead screw 47 mounted in frame 12 andhaving opposed left-hand and right-hand screw-threads 140 and 142,respectively, that cause co-operating rail supports 144 tosimultaneously advance toward or from the center of unit-feedersubassembly 16 depending on the direction of rotation of lead screw 47.Side rails 46 (see FIG. 2) are connected to and supported by adjustablerail supports 144.

FIGS. 11 through 13 illustrate details of the manually-operatedapparatus product-delivery gap adjustment mechanism 48 that is providedat the outer end of unit-feeder subassembly 16 to adjust the gap betweenunit-feeder subassembly 16 and unit picker subassembly 18 through whichproduct units are dispensed downwardly into chute 19. Adjustment of thegap ems that only one product unit is dispensed each time product unitdelivery apparatus 10 is actuated. n other words, such gap adjustmentachieves preferred apparatus picking of product units of differentthickness. Mechanism 48 includes a pair of joined feeder bed extensionrails 150 that are extended and retracted by co-operating lead screw152. Lead screw 152 in turn is driven by co-operating bevel gears 154and input shaft 156. Compression springs 158 are included to assure fullextension of extension rail elements 150. FIGS. 12 and 13 schematicallyillustrate the positioning of extension rail elements 150 forcomparatively thick and thin product units, respectively. Theadjustable-width apparatus product delivery gap which exists between thestop bars 76 of stop subassembly 72 and the projecting ends of extensionrails 150 is preferably just a little larger than the thickness of theproduct units to be picked by flight finger element 84. However, beforesetting the position of extension rail elements 150 to accommodate agiven product unit thickness change, it is necessary to properlyposition stop assembly 72 relative to unit-picker subassembly 74 so thatthe fingers attachments 84 attached to picker flight elements 82 projecta little less than the thickness of a product unit beyond the outer faceof stop bar elements 76.

Drawing details of apparatus mechanism 80 for adjusting the position ofstop subassembly 72 relative to the fixed position of unit-pickersubassembly 74 are best seen in FIGS. 2 and 4. Basically, threadedopenings in the frame 160 which supports and carries joined stop barelements 76 co-operates with frame-mounted lead screws 162 that eachcarry a key-joined sprocket 164. Endless chain 166 co-operates with eachsuch mechanism 80 sprocket. In addition, mechanism 80 includesco-operating bevel gears 168 that are attached to one of lead screws 162and to manually-turned input shaft 170. As suggested above, it isnecessary to properly adjust the position of stop bar elements 76relative to the path of flight finger elements 84 for properfinger-to-product unit initial contact before properly adjusting theposition of unit-feeder extension rails 150 relative to stop barelements 76.

We have also discovered that the picking of individual product unitsfrom a stack of very-thin product units such as printed pamphlets maypose a problem that arises out of lack of product unit stiffness orrigidity. To overcome this particular problem in apparatus 10 we utilizea multi-function flight finger 84. As shown in FIGS. 12 and 13, eachelement 84 in the picker-unit subassembly may be inverted from its FIG.12 orientation to its FIG. 13 orientation simply by rotating the elementabout its longitudinal rotational axis 180°. (Not detailed in thedrawings are the included conventional pivot and detent constructionfeatures that join picker finger element 84 to picker flight element 82to make that picker finger element invertible). Such inverting step thenpresents an included offset picker finger sloped end surface 172 to theproduct unit P upper edge at the moment of initial contact; such slopedend surface includes a lip segment that projects transversely and thatlast makes finger contact with the product unit P being picked to morepositively transport that product through the apparatus product deliverygap in a downward direction. Such has been observed to prevent theproduct unit being picked from otherwise buckling.

From an operating standpoint, apparatus 10 can function without thevelocity-modification linkage 100 being incorporated into drive shaft 92of unit-picker subassembly 74, although depending upon the overallproduct unit picking rate of apparatus 10, damage to product units mightoccur because of the large magnitude of product contact forcesassociated with very high picker flight and flight picker finger linearvelocities. The machine operating method introduced by utilization ofvelocity-modification linkage 100 involves the cyclical simultaneoussteps of: (1) operating electric motor 20 and the drive train 22connected to clutch mechanism 30 continuously; (2) upon receipt of acommand signal directing apparatus 10 to pick a product unit or sequenceof units from unit-feeder subassembly 16, activate clutch mechanism 30to thereby cause the prescribed number of complete revolutions of driveshaft 32, attached sprocket 34, and attached cam 36 to therebysimultaneously drive unit-feeder drive train 50 and unit-picker drivetrain 98; (3) advance the endless belts 40 of unit-feeder subassembly 16incrementally by the thickness of the number of product units in thecommand sequence and simultaneously, incrementally, and correspondinglyadvance the endless chains 86 and attached picker flights 82, the linearvelocity of each picker flight 82 being slowed to zero or near-zero atthe time of flight finger 84 contact with each product unit being pickedand immediately thereafter resuming its original linear velocity. Thisso-called “soft touch” feature of apparatus 10 is accomplished throughthe functioning of velocity-modification linkage 100 or another andalternate functionally equivalent device.

After picker flights 82 have moved through the prescribed or orderednumber of incremental chain 86 movements, their velocity is reduced tozero by the deactivation of clutch mechanism 30 in drive train 22. Thecycle is then ready for re-starting on receipt of the next commandsignal from the controlling order-filling system computer. To date wehave been able to achieve product unit picking rates of as much asapproximately 180 product units per minute.

Various changes may be made to the size, shape, and materials ofconstruction of the apparatus component parts described above withoutdeparting from the scope, meaning, or intent of the claims whichfollows.

We claim our invention as follows:
 1. Product unit-delivery apparatusthat incrementally selects and delivers different quantities of aproduct unit from a stack of product units in response tocomputer-controlled apparatus input signals received from an automatedorder filling system, and comprising, in combination: anadjustable-width apparatus product delivery gap having a pair of opposedsides; an apparatus product delivery chute co-operating with saidadjustable-width apparatus product delivery gap; a product unit-feedersubassembly contiguous to and defining the position of one side of saidadjustable-width apparatus product delivery gap, having a conveyor beltwhich supports a group of staked product units, and having a unit-feederdrive which incrementally advances said multiple conveyor belts towardsaid apparatus product delivery gap; a product unit-picker subassemblycontiguous to and defining the position of the other side of saidadjustable-width apparatus product delivery gap, having multipleproduct-picker flights which move on a path that intersects saidadjustable-width apparatus product delivery gap, and having aunit-picker drive which incrementally advances said multipleproduct-picker flights in response to a received apparatuselectrical/electronic input signal and into contact with product unitssupported and advanced by said product unit-feeder subassembly; and anapparatus drive having an intermittently activated/deactivated clutchmeans that movably power said product unit-feeder subassemblyunit-feeder drive and said product unit-picker subassembly unit-pickerdrive, said product unit-picker subassembly multiple product-pickerflights, when incrementally and sequentially advanced by said productunit-picker subassembly unit-picker drive and said apparatus drivemeans, causing rapid sequential downward movement of acomputer-controlled number of product units through said apparatusproduct adjustable-width delivery gap and into said apparatus deliverychute.
 2. The product unit-delivery apparatus defined by claim 1, andwherein said product unit-picker subassembly unit-picker drive furtherincludes a velocity-modification means modifying the linear velocity ofsaid product unit-picker subassembly multiple product-picker flightsduring operation of said product unit-picker subassembly unit-pickerdrive, said velocity-modification means reducing the velocity of saidproduct unit-picker subassembly product-picker flights to zero or nearzero velocity concurrent with each initial contact between one of saidmultiple product-picker flight and a product unit.
 3. The productunit-delivery apparatus defined by claim 2, and wherein said productunit-picker subassembly unit-picker drive includes a drive shaftfunctionally connected to and powering said unit-picker subassemblymultiple product-picker flights, and wherein said product unit-pickersubassembly unit-picker drive velocity-modification means is amechanical linkage which varies the rate of rotation of said productunit-picker subassembly unit-picker drive shaft.
 4. The productunit-delivery apparatus defined by claim 1, and wherein said productunit-picker subassembly unit-picker drive establishes a time-positionedpick-point in the linear path traversed by said product unit-pickersubassembly multiple product-picker flights, said product unit-pickersubassembly unit-picker drive pick-point being concurrent in time withinitial contact of a product unit-picker subassembly product-pickerflight with a product unit.
 5. The product unit-delivery apparatusdefined by claim 4, and wherein said product unit-picker subassemblyunit-picker drive includes an adjustable velocity-modification meansmodifying the linear velocity of said product unit-picker subassemblymultiple product-picker flights during operation of said productunit-picker subassembly unit-picker drive, said adjustablevelocity-modification means varying the time-position of thetime-positioned pick-point established by said product unit-pickersubassembly unit-picker drive when adjusted.
 6. The productunit-delivery apparatus defined by claim 5, and wherein said productunit-picker subassembly unit-picker drive includes anadjustably-positioned timing cam element, said adjustably-postionedtiming cam element, when repositoned, repositioning the timepositionedpick-point established by said product unit-picker subassemblyunit-picker drive to another time-position that is intermediate the timepositions of sequential activation/deactivation of said apparatus driveclutch means.
 7. The product unit-delivery apparatus defined by claim 1,and wherein said product unit-feeder subassembly includesadjustably-positioned extension rail elements interspersed with saidproduct unit-feeder subassembly multiple conveyor belts, and means forlongitudinally extending and retracting said extension rail elements,ends of said adjustably-positioned extension rail dements in-partdefining the position of one side of said adjustable-width apparatusproduct delivery gap.
 8. The product unit-delivery apparatus defined byclaim 1, and wherein said product unit-picker subassembly includes anadjustably-positioned product unit stop, and means for adjusting theposition of said product unit stop relative to said product unit-feedersubassembly, said product unit stop in part defining the position of oneside of said adjustably-width apparatus product delivery gap.
 9. Theproduct unit-delivery apparatus defined by claim 1, wherein said productunit-picker subassembly has an adjustably-positioned, product unit stopsubassembly that includes multiple, spaced-apart and substantiallyvertical, product unit stop bar elements, wherein said productunit-picker multiple product-picker flights have multiple, spaced-apartand attached, projecting product-picker fingers whose movement paths areinterspersed between said multiple, spaced-apart and substantiallyvertical, product unit stop bar elements, and wherein said productunit-picker subassembly includes means for adjusting the position ofsaid adjustably-positioned, multiple, spacedpart and substantiallyvertical, product unit stop bar elements, the positions of saidadjustably-positioned product unit stop subassembly stop bar elementsbeing interspersed with the position of the paths of said productunit-picker subassembly product picker flight projecting product-pickerfingers.
 10. The product unit-delivery apparatus defined by claim 9, andwherein the distance that said unit-picker subassembly product pickerflight attached spaced-apart product-picker fingers project beyond saidunit-picker subassembly product unit stop subassembly stop bar elementstoward said product unit-feeder assembly approximates but does notexceed the thickness of the product unit being picked.
 11. The productunit-delivery apparatus defined by claim 9, and wherein said productunit-picker multiple product-picker flight multiple, spaced-apart andattached projecting product-picker fingers are rotatable about alongitudinal axis and invertible relative to said unit-pickersubassembly product picker flights, said projecting product pickerfingers having sloped and lipped end surfaces that initially contact theproduct unit being picked.
 12. The product delivery-unit apparatusdefined by claim 1, and wherein apparatus drive includes anintermittently rotated drive cam, and wherein said product unit-feedersubassembly drive includes a product unit-feeder subassembly drive shaftrotationally connected to said product unit-feeder subassembly conveyorbelts, a product unit-feeder drive gear freely mounted on said productunit-feeder subassembly drive shaft, a one-way clutch device connectingsaid product unit-feeder subassembly drive gear to said productunit-feeder subassembly drive shaft, an adjustable-length reciprocatinglinkage connecting said apparatus drive cam to said product unit-feedersubassembly drive gear in motion transmitting relation, the length ofsaid adjustable reciprocating linkage being adjusted to impart, in onecomplete linkage motion cycle, one-way movement of said productunit-feeder multiple conveyor belts through a distance corresponding tothe thickness of the product unit being picked.
 13. An apparatus that isfor intermittently picking and delivering product units from a stack ofproduct units and that has a feeder conveyor which supports and feedsthe stack of product units toward a product unit stop and a pickerconveyor which has movable flights that intermittently contact andremove individual product units from the product unit stack, incombination, a product unit delivery gap positioned intermediate saidfeeder conveyor and said product unit stop and through which productunits and said picker conveyor flights pass when delivering productunits.
 14. The apparatus defined by claim 13, and wherein said feederconveyor and said product unit stop are movable relative to each otherand relatively moved to thereby change the width of said product unitdelivery gap.
 15. In a method of operating a product unit-deliveryapparatus having incrementally moved multiple product-picker flightsthat sequentially pick and transport for delivery a product unit from astack of product units, the step of causing each said product-pickerflight to initially contact its respective product unit with near-zerovelocity.